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Honda Motorcycle Service Manual
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:
Owner's manual
(131 pages)
,
User manual
(125 pages)
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Owner's manual
(16 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
How to Use this Manual
Symbols
Abbreviations
Carbon Monoxide
Gasoline
General Information Contents
General Safety
Hot Components
Nitrogen Pressure
Used Engine/Transmission Oil
Service Rules
Fasteners
Thread Sizes
Types of Threads
Hex-Head Bolt Strength Markings
Width Across Flats
"Torx" Bolt
CT Bolt
Torque Values (Tightening Force)
Fastener Loosening
Locking
Ball Bearing Replacement
Removing Ball Bearings
Installing Ball Bearings
Bearing Remover Compatibility for Wheel Bearing
Bearing Remover Compatibility Table
Bearing Size
Tool Compatibility Chart for Standard Bearings
Tool Compatibility Chart
Maintenance Contents
Fuel Line
Fuel Strainer Screen
Throttle Operation
Oil Pump and Oil Line
Oil Strainer
Carburetor Choke
Manual Choke
Starting Enrichment Valve
Air Cleaner
Oiled Urethane Foam Element
AIRCLEANER HOUSING DRAIN TUBE (Off-Road Motorcycles and Atvs)
Crankcase Breather
Paper Element
Replacing a Spark Plug
Reusing a Spark Plug
Spark Plug Inspection
Valve Clearance
4-Stroke, Wet Sump Engines
Engine Oil 2-1
4-Stroke, Dry Sump Engines
Leak Inspection
Oil Change
Engine Oil Filter 2-1
Cartridge-Type Paper Filter
Egine Oil Filter Screen
Element-Type Paper Filter
DECARBONIZING (2-Stroke Engine)
Carburetor Synchronization
Carburetor Idle Speed
Radiator Coolant
Cooling System
Level Check
Evaporative Emission Control System
Pulse Secondary Air Supply (Pair) System
TRANSMISSION OIL (2-Stroke Engine)
Transmission Oil Change
Drive Chain Adjustment
Adjustment of Pro-Arm Type
Cleaning, Inspection and Lubrication
Inspection of Chain Replacement Period
O-Ring Chains
Non O-Ring Chain
Refer T O the Model Specific Service Manual
Replacement of Endless Chain
Sprockets
Drive Belt
Drive Chain Slider, Chain Guide, Guide Slider and Rollers
Belt Case Air Cleaner
Final Drive Oil Level
Battery
Fluid Level
Specific Gravity of Fluid
Brake Fluid
Condition of Terminal Connections
Brake Pad Wear
Brake Shoe Wear
Brake System
Free Play Adjustment
Inspection for Air in System
Brake Pedal Height Adjustment
Hydraulic Brake Type
Date of Issue: March, 1995 HONDA MOTOR CO
Drum Brake Type
Brake Light Switches
Headlight Aim
Clutch System
On Centrifugal Clutch
Clutch Fluid Level
Conventional Type
Side Stand
Dual Motion Type
Inspection for Side Stand with Ignition Cut-Off Switch
Suspension
Nuts, Bolts, Fasteners
Spark Arrester
Wheels/Tires
Steering Head Bearings
Toe-In
Wheel Alignment
Camber/Caster
Engine Testing Contents
Service Information
Troubleshooting
Compression Testing
4-Stroke Leak-Down Test Information
Leak-Down Twsting
2-Stroke Pressure/Vacuum Leak-Down Test Information
Lubrication Contents
Lubrication Service Data
Lubrication Service Information
Lubrication Troubleshooting
4-Stroke Systems
System Description
Typical Oil Flow Pattern
Dry-Sump Type
Four-Stroke Engines
General
Wet-Sump Type
Separate Oil Systems
Two-Stroke Lubrication Systems
Premixed (Oil in Fuel) Systems
Oil Pump Descriptions
Trochoid Type
Oil Pump Operating Principle
Plunger Type
Oil Pressure Check
Oil Pump Inspection
In-Set Type Oil Pump
Pressure Relief Valve
Oil Pump/Oil Line Bleeding
Outlet Line Bleeding
Suction Line, Oil Pump Bleeding
Oil Cooler Inspection
Cooling System Contents
Cooling System Service Information
Cooling System Troubleshooting
Cooling System Descriptions
System Flow Patterns
Cooling Fan
Cooling Fan Switch
Radiator
Radiator Cap
Reserve Tank
Thermostat
Water Pump
Coolant Preparation
Coolant Replacement
Air Bleeding
Coolant Gravity Chart
Coolant System Testing
Hydrometer Test
Mechanical Seal Inspection
Radiator Cap Test
System Pressure Test
Water Pump Replacement
Exhaust System Contents
Exhaust System Service Information
Exhaust System Troubleshooting
Exhaust Pulse Scavenge Effect
Exhaust System Descriptions
Common Exhaust Pipe
Emission Control System Contents
Emission Control System Service Information
Emission Control System Troubleshooting
Crankcase Emission Control System
Emission Control System Descriptions
Source of Emissions
Exhaust Emissio Control System (Pulse Secondary Air Supply System)
Evaporative Emission (EVAP) Control System
Noise Emission Control System
Evaporative Emission Purge Control Valve (EVAP Purge Control Valve)
System Inspection
Evaporative Emmission Carburetor Air Vent Control Valve (EVAP Cav Control Valve)
Emission Control Information Labels
Pulse Secondary Air Injection Check Valve (Pair Check Valve)
Fuel Freshness and Troubleshooting
Fuel System Contets
Fuel System Service Information
Fuel System Troubleshooting
Carburetor
Fuel System Description
Principle of the Vacuum Piston Operated CV Type
Types of Carburetor
Float System
Operation of Systems
Starting System
HONDA MOTOR Co.,Ltd
Slow System (Low Degree of Opening)
Date of Issue: March, 1995
Accelerator Pump
Air Cut-Off Valve
Main System (Fully Open)
Main System (Medium Throttle Opening)
Fuel System
Reed Valve Inspection
Fuel Auto Valve
Fuel Auto Valve Inspection
Fuel Line
Carburetor Disassembly/Inspection
Throttle Valve Inspection (CV Type)
Throttle Valve/Starting Enrichment Valve Inspection
Starting Enrichment Thermal Valve
Starting Enrichment Thermal Valve Removal
Starting Enrichment Valve (Manual)
Throttle Valve (Piston Valve Type)
Vacuum Piston (CV Type)
Float/Jets
Carburetor Assembly
Carburetor Cleaning
Float/Jets Assembly
Float Level Inspection
Carburetor Separation/Assembly/Installation
Pilot (or Air) Screw Adjustment
Pilot (or Air) Screw Removal
Limiter Cap Type
Plug Type
Idle Drop Procedure
Pilot (or Air) Screw Adjustment 8-1
Pilot (or Air) Screw Installation
Air Screw or Pilot Adjustment
Best Idle Procedure
Limiter Cap (or Plug) Installation
Accelerator Pump Adjustment
High Altitude Adjustment
Cylinder Head Contents
Cylinder Head Service Information
Cylinder Head Troubleshooting
Cylinder Head Construction
Cylinder Head System Description
Valve Train
Example of DOHC with Valve Bucket Type
Example of SOHC-4 Valve System
Valve Lifter Mechanism /Arrangement
Hydraulic Tappets
Hydraulic Tappets Operation
Construction
Decompressor System
Description
Function of Decompressor System
Reverse Decompressor Cam
Camshaft Bearing Inspection
Camshaft Inspection
Camshaft Oil Clearance Inspection
Rocker Arm, Rocker Arm Shaft
Cylinder Head Inspection
Solvent Test
Warpage Inspection
Cylinder Head Disassembly
Valve Springs
Valves
Stem-To-Guide Clearance
Valve Guides Inspection
Valve Guides Replacement
When Using a Dial Indicator
Flangeless Type Guides
Valve Guide Reaming
Valve Seats Inspection
Inspect the Valve Seat Face
Valve Seat Refacing
Cylinder Head Assembly
Initial Camshaft Lubrication
Cylinder/Piston Contents
Cylinder/Piston Service Information
Cylinder/Piston Troubleshooting
Cylinder/Piston System Description
Piston
Piston Ring
Cylinder
Wear Inspection
Piston/Piston Ring Inspection
Piston/Piston Ring Removal
Piston Pin Inspection
Piston/Piston Ring Installation
Small End Bearing Surface Inspection
Piston Installation
Cylinder Installation
Clutch Contents
Clutch Service Information
Clutch Troubleshooting
Clutch System Descriptions
Wet Multiplate Manual Clutch (Type A: Outer Push Type)
Damper Spring Purpose
Judder Spring Purpose
Type B (Inner Push Type)
One-Way Clutch System (Type C: Inner Push Type with Back Torque Limiter Mechanism)
Operation
Power Flow Diagram
Type D (Crankshaft Mounted)
Type A: Shift Clitch Combined
Wet Multiplate Centrifugal Clutch
Gear Shift Lifter
Operation Principals
Type B: Separated Shift Clutch
Clutch Inspection
Clutch Lifter Disassembly/Inspection
Clutch Removal/Disassembly
Clutch Outer
Clutch Outer Guide, Needle Bearing
Lifter Plate Bearing
Clutch Disc
Lifter Push Rod
Lutch Center
Lutch Plate
Clutch Spring
Mainshaft
Udder Spring, Spring Seat
One-Way Clutch
Primary Drive Gear
Clutch Center Guide, Collar
Clutch Reassembly
Crankshaft
Clutch Lifter Reassembly
Fluid Replacement
Hydraulic Clutch System Service
Clatch Master Cylinder Removal/Disassembly
Clatch Master Cylinder Inspection
Clatch Master Cylinder Assembly/Installation
Clutch Slave Cylinder
Clutch Slave Cylinder Assembly
V-Matic Belt Drive System Service Information
V-Matic Belt Drive System Description
Drive Pulley Operation
Driven Pulley/Centrifugal Dry Clutch
Drive Belt Inspection
Drive Belt Installation
Drive Belt Removal
Drive Pulley Removal
Drive Pulley Disassembly
Drive Pulley Inspection
Dry Type
Wet Type
Drive Pulley Assembly/Installation
Drive Pulley Face Installation
Clutch/Driven Pulley Disassembly
Clutch Outer Inspection
Clutch Shoe Inspection
Driven Pulley Inspection
Driven Pulley Spring Inspection
Clutch Shoe Replacement
Driven Face Bearing Inspection
Driven Face Bearing Replacement
Clutch/Driven Pulley Assembly
Transmission Contents
Transmission Service Information
Transmission Troubleshooting
Gearshift Mechanism
Transmission System Description
Planetary Gear Type
Shift Finish
Shift Return
Shift Start
Constant Mesh Transmission
Bushings Cheking
Gears Checking
Transmission Disassembly
Transmission Inspection
Shift Drum Checking
Shift Fork Checking
Shift Fork Shaft Checking
Transmission Assembly
Crankcase/Crankshaft Contents
Crankcase/Crankshaft Service Information
Crankcase/Crankshaft Troubleshooting
Crankcase/Crankshaft System Descriptions
Crankshaft Inspection
Crankshaft Main Bearing
Radial Clearance (Assembly-Type Crankshaft Only)
Side Clearance
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How to Use this Manual
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See also:
Owner's Manual
,
User Manual
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Table of Contents
Troubleshooting
Engine testing contents
71
Lubrication troubleshooting
76
Cooling system contents
87
Exhaust system contents
97
Emission control system contents
101
Fuel system contets
111
Fuel system troubleshooting
112
Cylinder head contents
135
Cylinder/piston contents
155
Clutch contents
165
Transmission contents
213
Crankcase/crankshaft contents
221
Final drive/output shaft contents
233
Wheels/tires contents
253
Brakes contents
277
Front suspension contents
297
Rear suspension contents
321
Frame/body panels contents
333
Battery/charging/lighting system troubleshooting
357
Ignition systems connection
385
Electric starter/starter clutch contents
411
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